Ozone generator systems, methods, and apparatus

ABSTRACT

Corrosion Resistant Ozone Generators, including ozone generating chips, for various purposes including spas, pools and jetted tubs as well as methods for making and using such Corrosion Resistant Ozone Generators.

STATEMENT OF RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.14/752,579 having a filing date of 26 Jun. 2015, which is a division ofU.S. patent application Ser. No. 12/945,113 having a filing date of 12Nov. 2010, which claims priority on and the benefit of U.S. ProvisionalPatent Application No. 61/261,192 having a filing date of 13 Nov. 2009.

BACKGROUND OF THE INVENTION Technical Field

The present invention relates to systems, apparatus, and methods ofpurifying and disinfecting waters used in various applications,including but not limited to spas, jetted tubs, Jacuzzis, whirlpools,wave pools, baths, ponds, water tanks, swimming pools and the like. Moreparticularly, the invention relates to apparatus and methodsspecifically configured and adapted for the treatment, for example, forthe purification, of waters used in spas, jetted tubs, Jacuzzis,whirlpools, wave pools, baths, ponds, water tanks, swimming pools andthe like. In other embodiments, the invention may relate to systems,methods and apparatus for, without limitation, disinfecting foods (forexample, by spraying and/or washing produce with a liquid containing anon-toxic disinfectant) and laundry and other household items (such asin purifying waters used in washing machines, dishwashers and the likefor disinfection of clothing and other laundry.

The systems, apparatus, and methods of the present invention involve anozone generator, in particular, a Corrosion Resistant Ozone Generator,for generating ozone from the oxygen contained in air or otheroxygen-containing gasses. Such Corrosion Resistant Ozone Generators aresuitable for a variety of purposes, for example in air freshening andfor cleaning and disinfecting fluids such as aqueous fluids,particularly, although not exclusively, when the gas used as an oxygensource contains light amounts of nitrogen. Thus, such CorrosionResistant Ozone Generators are adapted for use in the systems, apparatusand methods relating to circulating water purifiers such as aJacuzzi-type tub or purifier, and in ozonized water generators, waterpurifiers and the like. The present invention also relates to aCorrosion Resistant Ozone Generator for generating ozone contained inair. The present invention thus relates to water purifiers equipped withan ozone generator for use with baths, swimming pools, Jacuzzis, ponds,water tanks and the like, for purifying water used in laundry andagricultural applications, and to Corrosion Resistant Ozone Generatorsfor generating ozone contained in air.

Prior Art

Systems, apparatus and methods of treating and disinfecting water are ofobvious and often critical importance. Access to safe water fordrinking, cooking, bathing, and washing is obviously a basic human need.To ensure such safe water, drinking water and water used for industrial,agricultural, household or recreational use is often and advantageouslypurified. Thus, for example, spas, jetted (hot) tubs, whirlpools, wavepools baths, ponds, water tanks, swimming pools and the like are oftentreated with active compounds to maintain the water therein in apurified or sanitized condition. These active compounds, such aschlorine and ozone, have been used to sanitize the relatively largevolumes, for example, hundreds or thousands of gallons, of water in suchspas, tubs, etc. As used herein, the terms “spa” and “jetted tub” referto systems which hold or contain a body of liquid aqueous medium,hereinafter referred to as water, which is often heated, in a reservoirwhich is smaller than a swimming pool, but is sufficiently large so thatan adult human being can be completely submerged or immersed in thewater contained in the reservoir. As used herein, Jacuzzis, baths,ponds, whirlpools, wave pools and swimming pools can be small or large,such that an adult human being, or several adult human beings can becompletely submerged or immersed in the water contained in thereservoir.

Spas, jetted tubs and pools are often used by submerging all or a majorportion of one's body in the water in the reservoir for recreationand/or relaxation. Additional, separate purifying or sanitizingcomponents are also included in these waters to control bacteria,viruses, algae, etc., which are known to contaminate such waters. Verylow concentrations of these active materials are used in order to avoidharming sensitive parts of the body—since such spas, tubs, pools etc.are sized so that the entire body can be immersed in the water and tominimize costs, because of the relatively large volume of water to betreated. For example, the normal (that is the typical, non-acutecontamination) concentration of ozone used to purify or sanitize thewater in a spa, tub or pool is often in the range of about 0.005 toabout 0.05 parts per million (ppm) based on weight of ozone per volumeof water (w/v).

Similarly, laundered fabrics are, by definition, soiled or dirty, andmay also contain bacteria, virus particles, algae and fungi. Water usedto launder clothing and other such fabrics is generally andadvantageously treated before and/or after use, for example, to avoidrecontamination of the fabrics or to lower the possibility of raisingthe infective load of such organisms in the environment.

Also, agricultural products, such as (without limitation) leafy produce(including lettuce, cabbage, parsley and the like), legumes (such asbeans and peas), tomatoes, tubers (such as potatoes, beets, radishes andthe like) all receive agricultural water, and various fertilizers. As aresult of the use of certain sources of water or fertilizers there havebeen reports of bacterial and viral contamination of such foodstuffs.Disinfection of water for watering through the use of disinfectingagents (e.g., ozone and/or chlorine) can help lower the likelihood offood contamination. Ozone is an ideal agent for such disinfection, sinceit decomposes quickly into molecular diatomic oxygen, and leaves noaftertaste or residue on the food.

For similar reasons, treatment of, for example, drinking water withozone provides water disinfection and purification without significantlyaffecting the taste of the water prior, for example to bottling.

Ozone (O₃) has conventionally been used in industrial as well ashousehold applications for purifying and deodorizing air, other gassesand the like. Ozone is an allotrope of oxygen, and is a relativelyhigh-energy molecule (and quite unstable) when compared to moleculardiatomic oxygen O₂, and decomposes to molecular oxygen according to theequation 2O₃→3 O₂ in about 0.5 hours under normal conditions at standardtemperature and pressure (STP). Ozone is a powerful oxidizing agent andthis ability contributes to its utility as a disinfectant.

Under natural conditions ozone is most plentiful in the atmosphere, in aregion of the stratosphere called the ozone layer, located between about6 and about 31 miles above the surface. Stratospheric ozone is producedfrom the interaction of ultraviolet rays with diatomic oxygen in thefollowing reactions:

O₂+photon→2O   (1)

O+O₂→O₃   (2)

For most personal and industrial uses, ozone is generated using an ozonegenerator. The easiest and most cost effective manner of generatingozone is using the “coronal discharge method”, in which high voltage isgenerated across a dielectric component located between two electrodes.A gap through which air or oxygen may be passed is also located betweenat least two electrodes. The spark generated across the dielectriccomponent causes the formation of free radicals of oxygen, andsubsequently the formation of ozone in a two-step reaction similar andcorresponding to the formation of ozone from diatomic oxygen shownabove.

Ozone generators are therefore generally known in the art. However, thegeneration of ozone creates certain problems particular to the process.Therefore, for example, high concentrations of ozone can be chronicallycorrosive to materials, such as (without exception) metals, alloys, andrubber. Further corrosion may be caused when air rather than pure oxygenis used as the source of diatomic molecular oxygen and nitrogencontaining salts and acids can be formed. All of this material canthereby shorten the useful life of an ozone generator and other relatedequipment, conduits, hoses, housings, contacts, fittings, pipes, wiresand the like located in close proximity to the ozone generator.

In response to this problem, Harter et al., U.S. Pat. No. 4,049,707constructed an ozone generator comprising a first electrode, a compositedielectric structure containing at least one layer of a first dielectricmaterial including overlapping, flat, plate like particles of an inertdielectric material located directly against a second electrode. Thefirst electrode and composite dielectrics structure are separated so asto define the gap. The gap comprises a chamber in which air or oxygenmay be permitted to flow, and in which ozone may be generated from theair or oxygen. Additionally, the surfaces of the first electrode and ofthe dielectric structure exposed to the gap are coated with a materialthat protects the interior surfaces of the gap. Harter discusses anozone generation having at least two different dielectrics, onecomprised of plate-like particles and in which the ozonation chamber iscoated with titanium dioxide.

As indicated above, in addition to the corrosive effect of ozone itself,when ozone is generated using air, which contains about 70% nitrogen,nitric acid is formed particularly when the air is moist or humid. Thisnitric acid also shortens the life of the entire ozone generator system.Similarly, under certain conditions ammonium nitrate may form on thedielectric, electrode(s) or other parts of the ozone generator.

In Lee et al., U.S. Pat. No. 6,730,277, an ozone generator is disclosedwhich is reported to be capable of producing ozone with much lessconsumption of electric power than previous models. The ozone generatorfeatures a pulse generator for generating high voltage pulses and adischarge chamber for inducing electrical discharge in response to thehigh voltage pulses. Electrical discharge takes place between electrodeplate and a grounded chamber wall; a sheet of oxide dielectric coversthe chamber wall to prevent corrosion of the chamber wall.

In Borgstrom et al., U.S. Pat. No. 6,726,885, an apparatus and methodfor generating ozone is disclosed in which a generally symmetricaldevice comprises a first electrode arranged along a longitudinal axis.The electrode is proximal to a first dielectric component on a top side,and a second dielectric component on a bottom side. A top coronaldischarge chamber and a bottom coronal discharge chamber are arrangedbetween the first dielectric and a top second electrode and the seconddielectric and a bottom second electrode.

Sali et al., U.S. Pat. No. 5,354,541, discloses an ozone generatorcomprising a helical spring anode within a sealed glass dielectric tube.And a metal tube cathode spaced across an annular gap from the glasstube.

Mechtersheimer, U.S. Pat. No. 4,960,570, discloses an ozone generator inthe form of a pair of outer electrodes and a tube or layer of tubeshaving a diameter corresponding to the space between outer electrodes,and having in each case an inner electrode. This configuration is statedto have the advantage of dispersing heat rather quickly.

Arlemark, WO97/01507, is said to have the advantage of being produced ina high frequency alternating current with high voltage over adielectric. Oxygen is introduced between two plates of aluminum oxideand a current is applied to an electrode net in the device.

Yomomi, U.S. Pat. No. 5,435,978, is directed to a plate like ozonegenerator comprising a plurality of discharging cells stacked one overthe other under pressure in a pressure vessel.

Morita et al., U.S. Pat. No. 6,039,816, discloses a compact ozonegenerator comprising three layers of a dielectric, in which the firstlayer has a filamentous electrode attached to the top surface, themiddle layer has an induction electrode on the surface thereof and thethird layer has a heating coil located on the top surface thereof. Theheating coil is for evaporating ammonium nitrate that may adhere to thedischarge unit when humid air is used as the oxygen supply. The threelayers are sandwiched together.

Ozone mixed with oxygen or air can be produced by passing oxygen gas(O2), for example, from a gas cylinder or an oxygen-containing gas, suchas atmospheric air or air from an air blower, by the high voltage“coronal” discharge method. Large-sized ozone generators for industrialuse generally employ pure oxygen or dry air as a starting material,whereas small-sized ozone generators for household or personal useemploy untreated air as a starting material. Such air-using ozonegenerators have the disadvantage, as discussed above, that when theozone generator is discharged continuously, corrosive or contaminatingnitrogenous compounds such as ammonium nitrate or nitric acid may formor be deposited on the electrodes or other portions of the ozonegenerator as a result of their reaction with nitrogen in air, resultingin corrosion or otherwise interfering with the function of the device.More particularly, because untreated air often has a humidity percentagehigher than that of artificially-produced dry air, large amounts ofnitrogen oxides can be produced when ozone is generated by discharge.

Accordingly, when so corroded or contaminated, the density of theelectric field generated by the ozone generator can be reduced. Also,salts such as ammonium nitrate covering the filamentary dischargeelectrode may tend to absorb water present in the air and becomeelectrically conductive, thus increasing the apparent area of one ormore electrode.

That is, in a conventional ozone generator, because salts and corrosivematerials such as nitric acid may corrode or cover the electrode(s) ofthe ozone generator, the density of the electric field generated by thefilamentary discharge electrode is reduced. The capacitance of thedielectric increases, resulting in reduced ozone generation.

Conventionally, therefore, the conventional ozone generator isperiodically disassembled, and adhering ammonium nitrate is wiped offfrom the filamentary discharge electrode using water or a solvent. Thatis, a conventional ozone generator must be maintained through manuallabor. After cleaning, the ozone generator resumes discharging tothereby generate ozone.

Typically, also, ozone is generated on site for use in, for example,applications including the purifying spa/tub/pool waters. Although ozonegenerators used for such service can, in addition to those employingcoronal discharge, include apparatus containing a sealed ultraviolet(UV) light lamp. Such conventional ozone generators are generallyeffective, in that they will produce ozone for oxygen-containing gasses.However, these generators do have certain drawbacks that other ozonegenerators disclosed elsewhere herein do not have. For example, the UVlight lamp is relatively bulky, can burn out (often requiring systemdisassembly and lamp replacement) and systems containing such lamps arerelatively inefficient in producing the desired amounts of ozone.

Therefore, it would be advantageous to provide new ozone generators thataddress these problems, and systems for purifying waters used forexample (and without limitation), in agriculture, food and drinkingwater applications, for household applications such as laundry (e.g.,washing machine) and dishwashing applications, spas, jetted tubs andpools comprising such ozone generators.

Each and every patent, patent publication and other publication cited inthis patent application is hereby incorporated by reference hereinindividually and in its entirety.

BRIEF SUMMARY OF THE INVENTION

Systems, methods and apparatus of the present invention employ aCorrosion Resistant Ozone Generator. By a “Corrosion Resistant OzoneGenerator” is meant an ozone generator that produces ozone using thecoronal discharge method and in which the inside surfaces of thedischarge chamber are entirely, or substantially entirely, made from adielectric, and in which the electrodes are entirely outside of thedischarge chamber. In preferred embodiments, the Corrosion ResistantOzone Generator used in the present invention is a compact, “chip”-likestructure made entirely from dielectric and insulating materials, withthe exception of the electrodes.

Thus, in a first preferred embodiment the invention involves a CorrosionResistant Ozone Generator that provides a very compact structure whichhas at least one, or at least two, or at least three, or all of thefollowing characteristics: is easily and conveniently mounted for use ina spa/jetted tub application; requires relatively reduced amounts ofmaintenance due to an anti-corrosion form of construction; is costeffective to produce and use; and effectively and efficiently producesozone in sufficient quantities to perform the desired spa/jetted tubpurification/sanitation service.

In other embodiments, the present Applicants have invented new systems,apparatus, and methods for purifying the waters in spas, jetted tubs,Jacuzzis, whirlpools, wavepools, baths, ponds, water tanks, swimmingpools and the like. The new systems employ ozone as apurifying/sanitizing component in a Corrosion Resistant Ozone Generatordescribed herein.

As indicated above, the ozone is generated using a Corrosion ResistantOzone Generator assembly which is resistant to compromise due tocorrosion commonly seen in ozone generators used in pools, spas, andtubs. Preferably, such Corrosion Resistant Ozone Generators aremanufactured to be durable, convenient, reliable, requires little or nomaintenance and generates ozone efficiently, for example, moreefficiently than a conventional UV light lamp ozone generator.Additionally, an advantage of certain embodiments of the CorrosionResistant Ozone Generator of the present invention is that they arecompact. Such an ozone generator is particularly effective in producingpurifying amounts of ozone for spas, jetted tubs and pools used forrecreation and/or relaxation. The systems and ozone generators of thisinvention effectively purify/sanitize water in these spas, jetted tubsand pools want is effectively purified/sanitized, with low cost andmaintenance, as discussed elsewhere herein.

In one broad aspect, the present apparatus is used for purifying thewater in a spa, jetted tub or pool, and comprises a Corrosion ResistantOzone Generator assembly and a transfer assembly. The CorrosionResistant Ozone Generator assembly is sized and adapted to purify thewater in a spa, jetted tub or pool, and includes a new CorrosionResistant Ozone Generator, as discussed in more detail elsewhere herein,which is adapted to produce ozone from air or other oxygen-containinggases using a voltage-generated coronal discharge. The transfer assemblycooperates with the ozone generator to pass oxygen to the CorrosionResistant Ozone Generator, and thence ozone produced by the CorrosionResistant Ozone Generator to the water in the spa, jetted tub or pool.

In a broad aspect, the present invention is drawn to ozone generators(Corrosion Resistant Ozone Generators) in which the gap or dischargechamber into which oxygen-containing gas (such as air) is fed is madeentirely or substantially entirely of a dielectric material. In aparticular preferred embodiment of the present invention, the dielectricmaterial is a ceramic material, such as an alumina ceramic; particularlypreferred is a ceramic having 90% or greater, or 92% or greater, or 94%or greater, or 95% or greater, or 96% or greater, or 97% or greater, or98% or greater of alumina. Electrodes are placed on either side of theoutside surface of the dielectric at a position preferably directly overthe discharge chamber within the Corrosion Resistant Ozone Generator,and a high voltage is applied to form a coronal discharge within thedischarge chamber, thereby first forming oxygen free radicals, and thenozone from the unreacted O2. The discharge chamber, the inside surfaceof which is made entirely or substantially entirely from a dielectric,has an air or gas inlet for oxygen-containing gasses) and an outlet forozone containing gases. The electrodes are connected via wiring to ahigh voltage transformer.

In certain embodiments of the present invention, the Corrosion ResistantOzone Generator assembly is formed as part of a Corrosion ResistantOzone Generator including a high-voltage-generating circuit element. TheCorrosion Resistant Ozone Generator may be present in a “chip” or “ozonecell” form, and may be disposed within a housing having a cover attachedso as to prevent ozone leakage from the housing.

In certain embodiments the present invention comprises a CorrosionResistant Ozone Generator which is easy to maintain and has an enhanceduseful life as compared to an ozone generator in which the dischargechamber is not made entirely or substantially entirely from adielectric. Also, in certain important embodiments the ozone generatormay be configured so as to provide ozone disinfection to a water oraqueous fluid system.

Furthermore, in certain embodiments of the present invention theCorrosion Resistant Ozone Generator is configured so as to provide ozonedisinfection to a water system using a compact, inexpensive, and easilymanufactured ozone generator that is resistant to corrosion, and inwhich the discharge chamber is made entirely or substantially entirelyfrom a dielectric.

Thus, in one broad aspect, the present invention provides a CorrosionResistant Ozone Generator having a discharge chamber, the interiorsurfaces of the discharge chamber being comprised entirely (orsubstantially entirely) of a dielectric material. In particularlypreferred embodiments the entire material surrounding the dischargechamber is made from a dielectric material.

Dielectric materials are materials having very low conductivity. Thesecan be gasses, liquids or solids. Dielectric materials may be comprisedof ceramics (such as porcelain), glass, plastics (such a polyethyleneand epoxides), industrial coatings such as parylene, hydrocarbon oils(such as mineral oil or electrical grade castor oil), silicone oils,mica, wood, the oxides of various metals, such as aluminum oxides, andpowdered dielectrics such as alumina, zircon, aluminum silicate,magnesium aluminum silicate, aluminum nitride, beryllia, zirconiumdioxide, titanium dioxide, magnesium silicate, tungsten carbide, and,preferably, barium titanate. These powdered dielectrics may in somecases be suitable for use in making ceramic dielectrics.

Particularly preferred in the present application are solid dielectricmaterials having a high degree of non-reactivity to ozone itself, aswell as to nitric acid or other nitrogenous by-products of the ozonationprocess when air is used as the oxygen source, particularly when the airis humid. Additionally advantageous is that the dielectric materialsused have a suitably high resistance to heat, and preferably compriseelements that have favorable heat dissipation characteristics. Suchmaterials may include dielectric ceramics, such as alumina andzirconium- and titanium-based ceramics, epoxides, mica-containingmaterials, such as mica-embedded polymers, other corrosion resistantpolymers and the like. Preferably the materials should be resistant tohigh voltage and electrical arcing.

It is particularly preferable that the dielectric material besubstantially homogenous. Additionally, and independently, it isparticularly preferable that the dielectric material used in the presentinvention be capable of being formed into substantially compact forms,such as plates, slabs, wafers, sheets and the like. Such materials mayinclude, without limitation, ceramic and polymeric materials.

In a preferred embodiment of the present invention, the CorrosionResistant Ozone Generator is structured from a plurality of wafers of adielectric; preferably the dielectric comprises a ceramic, mostpreferably an alumina ceramic material. The wafers all may be comprisedof the same dielectric, or two or more wafers may be comprised ofdifferent dielectrics.

For example, in one embodiment the Corrosion Resistant Ozone Generatormay be comprised of three dielectric wafers sandwiched together, withconductant plates, tubing, cylinders or tape able to withstand highvoltages and arcing and acting as electrodes and wires connecting theplates or cylinders etc. to each pole of a high voltage source. Thethree wafers may either be bonded together using a dielectric material,such as a thin film of epoxy resin or glue, or metal disposed directlyon the cylinder or plate, or alternatively may be held together in a“bundle” without being glued or bonded, for example, by using thecustomized tee fittings described below and in detail in the Examplesherein.

It will also be understood by those of skill in the art that theCorrosion Resistant Ozone Generator of the present invention need not besubstantially planar in every embodiment. For example, in certainembodiments the Corrosion Resistant Ozone Generator may comprise, forexample, a substantially cylindrical or tubular device having inner andouter cylindrical dielectric inserts of different diameters and acylindrical dielectric spacer insert sized and structured to fit betweenthe inner and outer cylindrical dielectric inserts, with suitable innerand outer electrodes, and one or more gas inlet and ozone outlet eachcontaining a void coextensive with a common inner void chamber formedbetween the dielectrics, the void chamber being structured to providefor corona discharge between the dielectrics and the generation ofozone. Other configurations of the Corrosion Resistant Ozone Generatorwill immediately be apparent to the skilled engineer.

Thus, in one embodiment of the invention, the center wafer of theCorrosion Resistant Ozone Generator has a substantially central opening,with the top wafer having segment of a proximal side of the wafer cutaway from it, and the bottom wafer having a segment of a distal side cutaway from it. The cut away portion of both the top and bottom wafers arepreferably identically shaped, so that the wafers are substantiallysuperimposable. Indeed, in one embodiment the top and bottom wafers areidentical, except that they are rotated along one axis such that the topsurface on the top wafer is the bottom surface of the bottom wafer.Also, preferably the sides of the cut out section of the top and bottomwafers are substantially the same width as the central opening of thecentral wafer.

In one embodiment of the present invention, one of the tee fittingscomprises a flat, elongated sleeve portion into which a proximal end ofthe sandwiched ceramic wafers will fit firmly, and a tube fittingportion, preferably barbed or in the form of a luer or other tubefitting, for the simple attachment of tubing or hosing, if desired, todraw air or oxygen into the ozone generator of the present invention.The void defined by the tube fitting portion of the tee fitting iscontinuous with the void defined by the flattened, elongated sleeveportion of the fitting.

A second, preferably identical tee fitting is used to hold a distal endof the sandwiched ceramic wafers together and to thereby direct ozonefrom the ozone generator to its desired application. Of course, in analternate embodiment the tee attached to the distal portion may be usedto draw air or gas, and the tee attached to the proximal end of thesandwich may be used to direct ozone to its desired application.

In one embodiment, the proximal end of the sandwiched ceramic wafers hasa top wafer with a cut out portion, wherein the sandwiched waferstogether define a continuous void wherein air or gas entering the teefitting may be drawn through the cut out portion into the dischargechamber defined by the central opening of the middle wafer, and finallythe ozonated air or gas may exit the ozone generator through the cut outportion of the bottom wafer and the connected tube fitting portion ofthe distal tee fitting. Those of skill in the art will immediatelyrecognize that the bottom wafer, rather than the top wafer, can be usedto draw air or gas into the central opening of the middle wafer, and thetop wafer, rather than the bottom wafer, can be used to direct ozonefrom the middle wafer to the desired application.

The customized tee fittings, described above and in the Examples herein,are made from a moldable material that has high insulation properties,is preferably strong, relatively heat-resistant, and is substantiallyresistant to chemical degradation caused by the by-products of ozoneformation. Any suitable material that provides these properties willfunction well in this embodiment of the Corrosion Resistant OzoneGenerator of the present invention. Preferably the material comprisespolyvinylidene fluoride (PVDF), sold under the trademark KYNAR®. Thismaterial has all the properties indicated above, and is a dielectricmaterial. PVDF can be injected, molded and welded very effectively.

Additionally, preferably a bonding material having high thermalstability, insulating ability, and high resistance to chemical damage(such as a silicone cement) is used to seal the ceramic/fittinginterfaces.

In other, presently less preferred, embodiments of the invention, thebody of the ozone generator can be made in any number of wafers,fragments, or pieces. For example, if the dielectric material issuitable for injection molding, the discharge chamber contained within asingle molded piece of a dielectric component can be fabricated havingchannels for the introduction of air and for the evacuation of ozone.Such an ozone generator may be used in conjunction with a fitting which,if in a shape different from that described for the preferred embodimentof the invention, can be specially fabricated from a dielectric materialsuch as PVDF to be used for the ozone generator.

Similarly, the shape and size of the ozone generator may be made to suitany desired application. When used for applications such as spas, jettedtubs, and small pools or other bodies of water, a ozone generator “chip”substantially as described previously will be preferred, since its sizeand shape are compact and yet suitable for use in these applications.However, where the amount of ozone required to be generated issubstantially greater than this, either a plurality of ozone generatorscan be used in series, in parallel, or as a combination of series orparallel may be used, or the size of the ozone generator, particularlyof the discharge chamber, can be increased.

Fabricating the ozone generator in three wafers or pieces substantiallyas described above may be one of the most cost effective and simple waysto manufacture the ozone generator of the present invention, since theneed for engineering of complex forms and a multiplicity of molds can beavoided in favor of relatively simple designs. Moreover, if generallynon-flowable dielectric materials are used (such as ceramics, whichusually have very favorable heat dissipation characteristics) the use ofinjection molding techniques may not be a practical manufacturingoption, and simple or more material-appropriate manufacturing methodsmust be used.

Thus, in another embodiment the present invention is directed to amethod of making an ozone generator comprising:

-   -   a. manufacturing a plurality of dielectric slabs (or wafers)        having substantially similar overall depth, length and width        dimensions, and having a first side and the second side, wherein        the length and depth of said slabs is substantially greater than        their width;    -   b. stacking together three of said slabs so that their sides        meet; wherein a middle slab comprises a central void completely        surrounded by dielectric material, wherein a top slab comprises        a first groove or void at a first edge, and wherein a bottom        slab comprises a in second groove or void at a second edge        opposite said first edge, thereby creating when the slabs are        stacked a single discharge chamber comprising a gas inlet and a        gas outlet comprising:        -   i. said first groove or void of the top slab, which is            coextensive with,        -   ii. the central void of the middle slab, which is            coextensive with,        -   iii. the second groove or void of the bottom slab, and;    -   c. placing a first high-voltage electrode on the outside surface        of the top slab,    -   d. placing a second high-voltage electrode on the outside        surface of the bottom slab;    -   e. providing means for directing an oxygen-containing gas        through the gas inlet into the discharge chamber and    -   f. providing means for directing an ozone-containing gas from        the discharge chamber through the gas outlet.

In a particularly preferred embodiment, the last two steps of the methoddescribed above can be accomplished using the customized tee fittingdescribed therein, or any other suitable fitting or combination offittings having the ability to simultaneously seal the gas inlet and gasoutlet and to direct gas into the inlet on one side of the sandwichedslabs, and to direct gas from the outlet on the opposite side of thesandwich slabs following coronal discharge and the generation of ozonefrom oxygen.

It will be apparent that in particular embodiments of the presentinvention the top and bottom slab used in the method described above maybe identical; in such case each of the two sides of the slab are alsoidentical, and the bottom slab can be rotated 180° as compared to thetop slab before inserting the middle slab between the top and bottomslab. The two sides of the top and bottom slabs may be identical becausethis slab is a homogeneous or relatively homogeneous material in whichthe surface and inside portions of the slab are substantially identical.Alternatively, the two sides of the top and bottom slabs may beidentical because the two sides of the slabs are coated with anidentical material. In this embodiment, currently less preferred, theinterior of the slab may be coated with a dielectric material on allexposed surfaces prior to assembly of the ozone generator.

One reason that this latter embodiment is less preferred is that itrequires substantially greater care and more steps in the manufacture ofan ozone generator than does the use of a homogeneous dielectricmaterial for fabrication of the slabs.

Depending upon the nature of the dielectric material used for the slabs,the grooves and central opening of the slabs described above can be madeby fabricating the slabs in molds that contain notches for the groove orvoid of the top and bottom slabs, and a separate mold comprising acentral projection for fabricating the middle slab with a central voidor opening.

Alternatively, the slabs used in the fabrication of the ozone generatorof the present invention can be fabricated as identical wafers or slabsfirst, and then shaped using cutting tools such as diamond saws orgrinders to form the notches or voids of the top and bottom slabs, andthe central opening of the middle slab. Of course, an advantage of thismethod is that the manufacture and assembly of the slabs in two thebasic ozone generator can easily be mechanized and assembled usingrobotic manufacturing equipment without the need for detailedquality-control procedures involving the intermediate steps ofmanufacture.

The electrodes used in the ozone generators of the present inventionshould be placed on opposite, preferably flat, sides of the assembleddevice, in each case substantially directly over the location of thedischarge chamber. It is particularly effective to place the electrodesin a generally centrally located position with respect to the outline ofthe discharge chamber underneath. If the electrodes are thus positioned,the resulting coronal discharge when a high-voltage electrical source isconnected to the electrodes will be more effective, thereby maximizingthe amount of ozone that can be generated within the discharge chamber.

In certain embodiments of the invention, two or more Corrosion ResistantOzone Generators in accordance with the present invention can beutilized together if larger volumes of water are to be treated, forexample for larger pools, large laundry purposes, or agriculturalapplications. In one particularly useful embodiment, accordingly, two ormore Corrosion Resistant Ozone Generator assemblies or two or moreCorrosion Resistant Ozone Generators, may be “teamed” together in aserial or parallel or a combination of serial and parallel configurationto provide enhanced ozone production to applications in which the amountof ozone required to be produced is higher. Examples of such embodimentsare provided in the Examples herein.

When two or more Corrosion Resistant Ozone Generators are used togetheras described above, the electrodes of each of the Corrosion ResistantOzone Generators is connected to a voltage source. Such plural use ofCorrosion Resistant Ozone Generators is generally effective to producesufficient ozone to purify (sanitize) the water in a spa, jetted tub orpool. For example, a single Corrosion Resistant Ozone Generator may beeffective to sanitize a spa, jetted tub or pool containing about 50 orabout 200 to about 1000 or about 5000 gallons of water. In anotherexample, about two to about five Corrosion Resistant Ozone Generatorsconnected either serially or in parallel, or in a combination of serialand parallel configurations may be effective to sanitize about 10,000 toabout 25,000 or about 50,000 gallons of water. In yet another example,about ten to about fifty ozone cells connected either serially or inparallel, or in a combination of serial and parallel configurations maybe effective to sanitize about 50,000 to about 100,000 or about 500,000or about 1,000,000 gallons of water.

In one particularly useful embodiment, the Corrosion Resistant OzoneGenerator preferably is connected to an electrical transformer sized,adapted and located to control the voltage provided to the CorrosionResistant Ozone Generator assembly. Often, the Corrosion Resistant OzoneGenerator operates on conventional alternating current. For example, thetransformer may be adapted to function by utilizing available ACelectrical power of about 100 to about 130 volts. In another embodimentthe line power utilized by the transformer is about 200 to about 250volts.

Alternatively, in other embodiments a 12 volt or 5-12 volt D.C. systemmay be employed to supply electric power.

The output of the transformer, that is the voltage provided by thetransformer and utilized in the Corrosion Resistant Ozone Generator tocreate the coronal discharge within the discharge chamber, may be fromabout 1000 volts to about 12,000 volts, preferably (though notnecessarily) in the range 2000 volts to about 8,000 volts, or about 2500volts to about 5000 volts, or about 3000 volts to about 4000 volts, orabout 3000 volts to about 3500 volts. It will be understood that thevoltage ranges indicated here are intended to, and do, specificallydisclose any point or pair of points included between the maximum andminimum voltages indicated herein.

Preferably, the Corrosion Resistant Ozone Generator utilized in thepresent invention is effective to produce sufficient ozone to purify(sanitize) the water in a spa, jetted tub or pool containing about 50 orabout 200 to about 1000 or about 5000 or about 25,000 or about 100,000or about 500,000 or about 1,000,000 gallons of water. The concentrationof ozone in the water in the spa, jetted tub or pool may generally be asnoted elsewhere herein.

Any suitable transfer assembly may be utilized provided that itfunctions to cooperate with the ozone generator to passoxygen-containing gas into the discharge chamber of the ozone generatorand ozone produced by the ozone generator to the water in the spa,jetted tub or pool.

As one example, the transfer assembly preferably makes use of a waterpump, water pipes, an eductor assembly and a transfer conduit. Theeductor (or venturi) assembly has an inlet and an outlet. The transferconduit is adapted to provide a passage for ozone-containing gases to betransferred from the ozone generator to the eductor assembly. The waterpump is positioned to pump water from the spa, jetted tub or poolthrough water pipes into the flow of which is positioned the eductorassembly. Due to the Venturi effect created by water flow through thewater lines in the eductor assembly created by the water pump, theeductor assembly creates a negative pressure within the transfer conduitat locations upstream of the eductor assembly. Thus, the passage ofwater through the water pipes causes ozone-containing gases from theCorrosion Resistant Ozone Generator to pass through the transfer conduitinto and through the eductor assembly and into the water flow.

The water pump can be, and preferably is, the pre-existing spa/jettedtub/pool water pump, that is the pump used to circulate water in thespa/jetted tub/pool. In one useful embodiment, the eductor assembly islocated in a bypass conduit of the water pipes having a constrictionthat increases water flow; a minor amount, that is less than about 50%,of the water being pumped by the water pump is passed through the bypassline.

The transfer assembly preferably includes water pipes which circulatewater from and to the spa or jetted tub or pool, and a filter locatedupstream of the eductor assembly in fluid communication with the waterpipes and adapted to remove solid or particulate matter from the waterpassing through the water transfer line. The transfer assemblypreferably further includes a heater adapted to heat the water flowingthrough the water transfer line upstream of the eductor assembly;however this feature is not necessary to the function of the ozonegenerator or the disinfection of water in the jetted tub, spa or pool.

In one embodiment, the ozone transfer conduit is configured to reducethe probability of water passing from the eductor assembly to the ozonegenerator. This feature is designed to avoid detrimentally affecting theozone generator. For example, the ozone transfer conduit may include awater trap. The ozone transfer conduit may include a loop (for example,a water trap loop), preferably located above the eductor assembly, toreduce the risk of water contacting the Corrosion Resistant OzoneGenerator. The Corrosion Resistant Ozone Generator assembly housingpreferably is located above the water level in the spa/jetted tub.

The ozone transfer conduit may include a check valve (such as a “one-wayvalve”), for example, of conventional design adapted to prevent fluidflow in the ozone transfer conduit toward the ozone generator.

Those of ordinary skill in the art can readily see that the CorrosionResistant Ozone Generator system described herein in the context of asystem for disinfecting water used in jetted tubs, spas and pools can belargely adapted wholesale, or with minor variations, to otherapplications, such as laundry applications and agriculturalapplications. As described above, the use of water flow to create anegative pressure in a Venturi can be utilized to introduce ozone intothe flowing water, and can simultaneously be used to draw air oroxygen-containing gas into the Corrosion Resistant Ozone Generator.Alternatively, the systems may comprise fans or pumps to move or helpmove air, gas, or ozone through the Corrosion Resistant Ozone Generatorand into the water. Washing machines can either be manufactured withsuch Venturis plumbed into the water transfer system, or theintroduction of an ozone generator into such systems can be retrofitted.Also, the Corrosion Resistant Ozone Generator assembly, including thehousing can usually be made to be compact enough to fit within thewashing machine housing or a dishwasher housing. Similarly, foragricultural applications, the Corrosion Resistant Ozone Generatorassembly can easily be placed near the water supply pump for washing orwatering produce using the disclosure provided above as a guide.

Methods for purifying/sanitizing waters located in spas, jetted tubs andpools, in washing machines, dishwashers, and for agricultural purposesare included within the scope of the present invention. Preferably,these methods comprise employing the present apparatus to provide apurifying/sanitizing amount of ozone to the water used in any suchapplication.

Any combination of two or more features described herein are includedwithin the scope of the present invention provided that the features ineach such combination are not mutually inconsistent. Furthermore theinvention is not limited to any example described herein, but is definedsolely by the claims.

These and other aspects and advantages of the present invention aredisclosed in the following detailed description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the figures, like reference numerals refer to like parts throughoutthe various views unless otherwise indicated. For reference numeralswith letter character designations such as “102A” or “102B”, the lettercharacter designations may differentiate two like parts or elementspresent in the same figure. Letter character designations for referencenumerals may be omitted when it is intended that a reference numeral toencompass all parts having the same reference numeral in all figures.

FIG. 1 is a generally schematic illustration showing an embodiment ofthe Corrosion Resistant Ozone Generator assembly housing in use inpurifying the water in a spa.

FIG. 2 is a planar view of the Corrosion Resistant Ozone Generatorassembly housing used in the embodiment shown in FIG. 1 with the housingcover removed.

FIG. 3 is a planar view of the inner surface of the housing cover of theCorrosion Resistant Ozone Generator used in the embodiment shown in FIG.1.

FIG. 4 is a top planar view of the components of the Corrosion ResistantOzone Generator used in the embodiment in FIG. 1.

FIG. 5 is a top planar view of the Corrosion Resistant Ozone Generatorused in the embodiment shown in FIG. 1.

FIG. 6 is a top planar view of an ozone generator of the presentinvention employing three Corrosion Resistant Ozone Generators in aserial configuration.

FIG. 7 is a top planar view of an ozone generator of the presentinvention employing three Corrosion Resistant Ozone Generators in aparallel configuration.

FIG. 8 is a top planar exploded view of the components of an alternativeembodiment of the Corrosion Resistant Ozone Generator of the presentinvention.

FIG. 9 is a top planar view of the components of the alternativeembodiment of the Corrosion Resistant Ozone Generator of the presentinvention shown in FIG. 8.

FIG. 10 is an exploded view of a housing for the alternative CorrosionResistant Ozone Generator shown in FIG. 8 and FIG. 9.

FIG. 11 is an example of a series multi-chip configuration using theCorrosion Resistant Ozone Generator of Example 6.

FIG. 12 is an example of a parallel multi-chip configuration using theCorrosion Resistant Ozone Generator of Example 6.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Aspects, features and advantages of several exemplary embodiments of thepresent invention will become better understood with regard to thefollowing description in connection with the accompanying drawings. Itshould be apparent to those skilled in the art that the describedembodiments of the present invention provided herein are illustrativeonly and not limiting, having been presented by way of example only. Allfeatures disclosed in this description may be replaced by alternativefeatures serving the same or similar purpose, unless expressly statedotherwise. Any aspect described herein as exemplary is not necessarilyto be construed as exclusive, preferred or advantageous over otheraspects.

EXAMPLE 1

Referring now to FIGS. 1-3, one configuration of the system of thepresent invention, shown generally at 10, includes a Corrosion ResistantOzone Generator assembly housing shown generally at 12, and a transferassembly, shown generally at 14. The Corrosion Resistant Ozone Generatorassembly housing 12 is surrounded by a housing body 16 and a housingcover 18 which is adapted to be joined or connected to the housing bodyby coupling threaded inserts 20 through complimentary cover holes.

With housing cover 18 secured to housing body 16, ozone generator 12 iscontained within and protected by a compact, closed unit. Located withinthe space 24 between the housing body 16 and housing cover 18 is aCorrosion Resistant Ozone Generator 26. Ozone-containing gases producedby Corrosion Resistant Ozone Generator 26 from air entering housing body16 through air inlet 27 exit the housing through housing outlet 28,which can be an integral part of the housing body 16. The air inlet may,and preferably does, include a particulate filter, for example, ofconventional construction. The air inlet may provide for uptake of airfrom the atmosphere, uptake of air from an air blower or uptake ofoxygen from an oxygen tank. Furthermore, the air inlet may comprise anair dryer, such a heater or an anhydrous material capable of removingwater from the air drawn through it. Both the housing body 16 andhousing cover 18 can be made from any suitable material or materials ofconstruction. Preferably, these components are made of polymericmaterial. For spas, jetted tubs and small pools the Corrosion ResistantOzone Generator housing 12 typically has a length in a range of about 4inches to about 10 inches, a width in a range of about 1 inch to about 6inches and a thickness of about 0.5 inch to about 4 inches.

An electrical transformer 30, of conventional design, is typicallyincluded within space 24. Electrical transformer 30 processes linepower, e.g., 120V, from source 32 through power cord 33 and transformsthis line power into power suitable for use by the Corrosion ResistantOzone Generator 26. Transformer 30 is a “step up” transformer; in thisembodiment of the invention Corrosion Resistant Ozone Generator 26 usespower having a voltage in the range of about 1000 to 12,000 volts,preferably about 3000 to about 5000 volts, more preferably in the rangeof about 3000 to about 3500 volts. A series of electrical connectors 33,34 and 36 are optionally included within space 24 and are adapted toconnect electric wires so as to provide electric power from source 32and ultimately transfer the power to the Corrosion Resistant OzoneGenerator 26. These connectors are adapted to be easily removed to allowmaintenance of the system contained within housing 12. A variablepotentiometer 37 is optionally provided and is used to control or adjustthe ozone output of Corrosion Resistant Ozone Generator 26 withinhousing 12.

In addition, the housing cover 18 of this embodiment includes two endtabs 44 and 46, each of which includes a through hole 48 through whichscrews can be passed to secure the Corrosion Resistant Ozone Generatorhousing 12 in place in a suitable stationary position.

The present system comprising the Corrosion Resistant Ozone Generator 26operates as shown in FIG. 1. Spa 50 includes a quantity of heated andcirculating water 52, for example, about 500 to 1000 gallons in volume.The spa 50 is equipped with a water circulating system in which waterfrom the spa passes through spa outlet 54 into conduit 56 through spapump 58, spa filter 60 and spa heater 62. Eventually the pumped,filtered and heated water is passed back to the spa 50 through returnlines 64 and 66.

In the present invention, piping segment 70 (a part of conduit 56),downstream of heater 62 is divided to provide a bypass line, showngenerally at 72. Bypass line 72 includes a venturi assembly 74, ofgenerally conventional construction, which acts as an ozone eductor tosuction ozone-containing gases from the Corrosion Resistant OzoneGenerator 26 in housing 12 into bypass line 72. The combinedozone-containing gases and water is returned to the main water conduit56, as shown in FIG. 1. A valve 78, of conventional design, is locatedin water conduit 79 and can be adjusted to control the amount of waterpassed through bypass line 72. The ozone-containing gases from CorrosionResistant Ozone Generator 26 are passed through housing outlet 28 andthrough ozone conduit 80 into the water flowing through bypass line 72.The suction created by venturi assembly 74 causes ozone to flow throughozone conduit 80.

Ozone conduit 80 includes a water trap loop 82 located above venturiassembly 74. This water trap loop 82 acts to protect the ozone generatorfrom being exposed to water in line 56 and bypass line 72. In addition,ozone conduit 80 includes a one-way check valve 84, of conventionalconstruction, which effectively prevents fluid from flowing in the ozoneconduit back to the ozone generator 12. This feature inhibits, or evensubstantially prevents, any water from line 56 and bypass line 72 fromentering ozone generator 12.

Another embodiment of the claimed system is shown in FIG. 1. Apparatus10 functions as follows. When it is desired to purify/sanitize the water52 in spa 50, operation of the pump 58 and Corrosion Resistant OzoneGenerator 26 is initiated. This causes water 52 to flow from spa 50through line 56 into pump 58, optional filter 60, and optional heater 62into piping segment 70. At this point, a minor amount, that is, lessthan about 50%, of the total water passing through segment 70 is causedto flow through bypass line 72 and venturi assembly 74. This causesozone-containing gases being generated by Corrosion Resistant OzoneGenerator 26 to pass through ozone conduit 80 into the water in bypassline 72, which is ultimately returned to the spa via return line 64 and66.

Sufficient ozone is produced in accordance with the present invention topurify/sanitize the water 52 in spa 50 and/or to maintain such water inthe desired purified/sanitized state.

EXAMPLE 2

This example describes the components of one embodiment of the CorrosionResistant Ozone Generator 26 which can be used in the system of thepresent claims.

As shown in FIG. 4, the chip electrode assembly has a center wafer 101made entirely of a dielectric; this wafer is a “spacer” wafer positionedbetween a top wafer 103 and a bottom wafer 105. In this embodiment thespacer wafer 101 is made of 96% alumina ceramic. The spacer wafer 101has a substantially central opening 107. The top wafer 103, in this casealso made of 96% alumina ceramic, has a segment of a proximal side ofthe wafer cut away from it 109, and the bottom wafer 105, made of 96%alumina ceramic, and having a segment of a distal side cut away from it111.

Those of ordinary skill in the art will be aware that the spacer wafer,top wafer and bottom wafer may be comprised of other ceramic dielectricsor even other non-ceramic dielectrics; moreover, in other embodiments,one or more wafer may be comprised of a different dielectric than thatof another other wafer.

The cut away portions of both the top and bottom wafers are preferablyidentically shaped, so that the wafers are substantially superimposable.In this case the top and bottom wafers are identical, except that theyare rotated along one axis such that the top surface on the top wafer103 is the bottom surface of the bottom wafer 105. The sides of the cutout section of the top and bottom wafers are substantially the samewidth as the central opening of the central wafer.

Tee fitting 113, made from a moldable material comprising polyvinylidenefluoride (PVDF), sold under the trademark KYNAR®, comprises a flat,elongated sleeve portion 115 defining a void 116, into which a proximalend of the sandwiched ceramic wafers will fit firmly, and a tube fittingportion 117, to draw air into the discharge chamber 129 (shown in dottedlines in FIG. 5) formed by the sandwiched top, spacer and bottom wafers101, 103 and 105.

The void 119 defined by the tube fitting portion of the tee fitting iscontinuous with the void 116 and identical void (not shown) created byidentical tee fitting 113′ described below is shown defined by theflattened, elongated sleeve portion of the fitting.

Another identical tee fitting 113′ is used to hold a distal end of thesandwiched ceramic wafers together and to thereby direct ozone from thedischarge chamber 129 formed by the sandwiched top, spacer and bottomwafers 101, 103 and 105 to its desired application. The space in thedischarge chamber is defined by the substantially central opening 107 incentral wafer 101 continuous with the cut away segments 109 and 111 ofthe top and bottom wafers respectively, and is shown in dotted lines inFIG. 5.

Copper electrode 121′ is placed on the outside surface of the top wafer103 and an identical copper electrode 121 is placed on the outsidesurface of bottom wafer 105. The electrodes 121 and 121′ are connectedvia wiring 123 and 123′ to each pole of a high voltage transformer. Thecopper electrodes may comprise adhesive-backed copper tape affixed to aside of the Corrosion Resistant Ozone Generator 26 to which copper wireof an appropriate gauge is welded, soldered or otherwise retained, at127 and 127′ on the bottom and top wafers, respectively. The electrodesare preferably placed on a location on the outside surface of the topand bottom wafers that is substantially centrally located with respectto the discharge chamber 129 within the sandwiched wafers 101, 103 and105.

EXAMPLE 3

As shown in FIG. 5, the components shown in FIG. 4 are assembled to formthe Corrosion Resistant Ozone Generator 26, as used in the embodiment ofthe system of the present invention shown in FIG. 1. The CorrosionResistant Ozone Generator is comprised of the three wafers, namely, atop wafer 103, center wafer 101 and bottom dielectric wafer 105, thatare sandwiched together, with conductant metal tape or plates 121 (notshown) and 121′ acting as electrodes and wires 123 and 123′ (not shown)connecting the plates to each pole of a high voltage source. Theconductant plates or tape are located substantially centrally on each ofthe top surface of the top wafer and the bottom surface of the bottomwafer such that when assembled, they substantially superimpose upon eachother and are in addition substantially centrally located with respectto the middle wafer 101 in alignment with to the central opening in themiddle wafer, as shown in FIG. 5. These conductant plates are eitheradhered to the surfaces of the bottom and top wafers or metallized ontothe surfaces of the top and bottom wafers. Wires 123 and 123′ aresoldered, welded or otherwise affixed to these conductant plates or tapeto form electrodes. The three wafers are held together in a “bundle” byusing the two customized tee fittings 113 and 113′.

In addition, the Corrosion Resistant Ozone Generator 26 is sealed, viaeither a silicone or other sealant around the tee fitting and ceramicinterface to prevent leakage of air and/or ozone containing gases fromthe electrode assembly.

When a high voltage is applied across electrodes 123 and 123′ to form acoronal discharge, oxygen from the air enters the tee fitting 113through the tube fitting 117 and enters the discharge chamber throughthe cut out portion 109 of the top wafer 103 and first forms oxygen freeradicals, and then the free radicals combine with unreacted O2 to formozone in the discharge chamber 129, which then exits the ozone generator26 through the cut out portion of the bottom wafer and the connectedtube fitting porting 117′ of the distal tee fitting 113′. The insidesurface of the walls of the discharge chamber is thus made entirely orsubstantially entirely from 96% alumina ceramic dielectric. As describedin Example 2, the discharge chamber is defined by the substantiallycentral opening 107 in central wafer 101 continuous with the cut awaysegments 109 and 111 of the top and bottom wafers respectively, and isshown in dotted lines.

EXAMPLE 4

As shown in FIG. 6, three chip Corrosion Resistant Ozone Generators 26a, 26 b and 26 c, whose individual components are described in Examples2 and 3 and FIG. 3, and are assembled as in FIG. 4, are connected in aserial configuration in order to generate sufficient ozone required tosanitize a pool. An ozone generator comprising such a serialconfiguration of chip electrodes/ozone cells is used in the embodimentshown in FIG. 1.

In this embodiment, the three Corrosion Resistant Ozone Generators areconfigured such that the each set of electrodes of each cell areconnected to a different voltage source, and are all housed together ina single housing chamber. In the alternative, Corrosion Resistant OzoneGenerators may be configured such that all the electrodes of eachindividual Corrosion Resistant Ozone Generator are connected to a singlevoltage source. In another variation, each individual CorrosionResistant Ozone Generator may be housed in different housing chambers. ACorrosion Resistant Ozone Generator comprising such a serial arrangementof three individual ozone generators functions as follows. Air is drawnthrough air inlet 27 in the housing chamber 16 and enters via tube 131connected to tube fitting portion 117 a of ozone generator 26 a. Theozone containing gases produced by ozone generator 26 a exit via tube132 connecting the tube fitting portion 117 a′ of ozone generator 26 aand tube fitting portion 117 b of second ozone generator 26 b. Theoxygen (and ozone)-containing gases entering ozone generator 26 b viatube fitting portion 117 b get further enriched in ozone and exit viatube 133 connecting the tube fitting portion 117 b′ of ozone generator26 b and enter third ozone generator 26 c via tube 133 connected to tubefitting portion 117 c. Gases sufficiently enriched in ozone to sanitizea pool of the desired water volume exit through tube fitting portion 117c′ and further through tube 134 and further, housing outlet 28 to thepool water supply. It will be understood by those of ordinary skill inthe art that the number of Corrosion Resistant Ozone Generators linkedin serial fashion in this way is discretionary according to the amountof ozone desired to be produced, with the only limiting factor being thegradual depletion of oxygen from the air or gas supply introduced at airinlet 27 as a function of an increase in the number of ozone generatorslinked in series.

EXAMPLE 5

As shown in FIG. 7, three corrosion Resistant Ozone Generators 26 d, 26e and 26 f, whose individual components are described in Examples 2 and3 and FIG. 3, and are assembled as in FIG. 4, are connected in aparallel configuration in order to generate sufficient ozone required tosanitize a large Jacuzzi. A Corrosion Resistant Ozone Generator assemblyhousing 12 comprising such a parallel configuration of individual ozonegenerators is used in the embodiment shown in FIG. 1.

In this embodiment, the individual Corrosion Resistant Ozone Generatorsare configured such that both the electrodes of each corrosion ResistantOzone Generator are connected to a different voltage source, and are allhoused together in housing chamber 26. In the alternative, CorrosionResistant Ozone Generators may be configured such that all theelectrodes of each individual Corrosion Resistant Ozone Generator areconnected to a sin voltage source. In another variation, each individualCorrosion Resistant Ozone Generator may be housed in different housingchambers. A Corrosion Resistant Ozone Generator comprising such aparallel arrangement of three Corrosion Resistant Ozone Generatorsfunctions as follows. Air is drawn from inlet 27 in the housing chamber16 and enters the system via three tubes 135, 136 and 137 connected totube fitting portions 117 d, 117 e and 117 f of ozone generators 26 d,26 e and 26 f, respectively. The ozone containing gases produced byozone generators 26 d, 26 e and 26 f exit via three tubes 138, 139 and140 connecting the ozone generators 26 d, 26 e and 26 f respectively,and finally exit the housing chamber at outlet 28. Gases enriched inozone sufficiently to sanitize a large Jacuzzi are produced at theoutlet 28. While these series and parallel arrangements are show, anycombination or configuration of series and/or parallel plumbing can beused.

EXAMPLE 6

As another non-limiting example, FIG. 8 shows an alternativeconfiguration of the ozone generator chip of the present invention. Inthis embodiment a base component 200, molded from corrosion-resistantmaterial, has both the gas inlet 202 and the ozone outlet 204 built in,and a cavity 206 for the dielectric components. Ozone-resistant o-rings208 fit into the base component 200 aligned with holes leading into andout of the base. The o-rings seal against the bottom dielectric wafer210, which has holes 212 at either end to align with the o-rings. Theconfiguration and dimensions of the spacer 214 may be similar to that ofthe ozone generator chip shown in previous examples. The top dielectricwafer 216 is flat with no flow cuts.

The top and bottom dielectric wafers 210 and 216 and spacer 214, as wellas the bottom 218 and top 220 electrodes are sandwiched together asbefore, with the electrodes and wires 224 on the outer surfaces of thesandwich. A clip 222 forces and holds the assembly together, and theentire cavity is potted with a thermally conductive epoxy material Anindicator light 226 is secured to the clip but no electrical connectionsare made, since the light is illuminated and induced by the electricfield of the ozone assembly.

FIG. 9 shows the entire Corrosion Resistant Ozone Generator assemblyassembled and clipped together. FIG. 10 shows the Corrosion ResistantOzone Generator chip assembly of this embodiment installed in aprotected, gasket-sealed moisture resistant housing assembly similar infunction to that shown in FIG. 1p ; in this case the housing body 300 isconfigured to hold the assembled Corrosion Resistant Ozone Generator 304by means of a clip 306 which fastens over the Corrosion Resistant OzoneGenerator and two raised brackets 308 on the inside surface of thehousing body. A gasket fits within a roughly circular, polygonal, orovoid race 312 on the inside of both housing body 300 and housing cover302, thereby preventing substantial infiltration of moisture. Holes onthe inside of each the housing body and the housing cover 314, sealedusing O-rings 316, provide access to the air inlet and ozone outlet ofthe Corrosion Resistant Ozone Generator. The assembly is screwedtogether.

FIG. 11 and FIG. 12 show non-limiting possible parallel and seriesplumbing configurations, respectively, involving multiple chips of thisembodiment of the invention.

While this invention has been described with respect to various specificexamples and embodiments, it is to be understood that the invention isnot limited thereto and that it can be variously practiced within thescope of the following claims.

What is claimed is:
 1. A method of making an ozone generator comprising:a) manufacturing a plurality of dielectric slabs or wafers havingsubstantially similar overall depth, length and width dimensions, andhaving a first side and the second side, wherein the length and depth ofsaid slabs is substantially greater than their width; b) stackingtogether three of said slabs so that their sides meet; wherein a middleslab comprises a central void completely surrounded by dielectricmaterial, wherein a top slab comprises a first groove or void at a firstedge, and wherein a bottom slab comprises a second groove or void at asecond edge opposite said first edge thereby creating, when the slabsare stacked, a single discharge chamber comprising a gas inlet and a gasoutlet, wherein: i) said first groove or void of the top slab iscoextensive with, ii) the central void of the middle slab, which iscoextensive with, iii) the second groove or void of the bottom slab,and; c) placing a first high-voltage electrode on the outside surface ofthe top slab, d) placing a second high-voltage electrode on the outsidesurface of the bottom slab; e) providing means for directing anoxygen-containing gas through the gas inlet into the discharge chamber,and f) providing means for directing an ozone-containing gas from thedischarge chamber through the gas outlet.
 2. The method of making anozone generator of claim 1, wherein the stacking together three of saidslabs additionally comprises providing at least two tee fittings, eachrespectively comprising a flat, elongate sleeve portion and a tubefitting portion, one in between two stacked slabs and the other inbetween the other two stacked slabs, wherein the tee fitting isconfigured to cooperate with the groove or void of the respectivestacked slabs, thereby, when the slabs are stacked, sealing the gasinlet and gas outlet, and directing gas into the inlet on one side ofthe respective stacked slabs, and directing gas from the outlet on theopposite side of the respective stacked slabs, following coronaldischarge and the generation of ozone from oxygen.
 3. The method ofmaking an ozone generator of claim 2, wherein the stacking togetherthree of said slabs additionally comprises maintaining the bundle ofstacked slabs together via the at least two tee fittings, with theproviso that not glue or bonding agent is used.
 4. The method of makingan ozone generator of claim 2, wherein the tube fitting portion of eachof the at least two tee fittings is configured to be barbed or luered.5. The method of making an ozone generator of claim 2, wherein a voiddefined by the tube fitting portion of each of the at least two teefittings is continuous with a void defined by the flat, elongate sleeveportion of each of the at least two tee fittings
 6. The method of makingan ozone generator of claim 1, wherein the manufacturing a plurality ofdielectric slabs additionally comprises manufacturing the top slab andthe bottom slab such that they are identical, such that the bottom slabcan be rotated 180° as compared to the top slab before inserting themiddle slab between the top and bottom slab.
 7. The method of making anozone generator of claim 1, wherein the manufacturing a plurality ofdielectric slabs additionally comprises manufacturing the groove or voidof the top and bottom slabs via molds, the molds defining notchescorresponding to the groove or void of the respective slab, andmanufacturing the middle slab via a second mold comprising a centralprojection for fabricating the central void of the middle slab.
 8. Themethod of making an ozone generator of claim 1, wherein themanufacturing a plurality of dielectric slabs additionally comprisesmanufacturing the slabs such that they are identical, and thenmanufacturing the top slab and the bottom slab via a cutting tool tomachine into the respective slab the groove or void characterizing thetop and bottom slabs, and the central void characterizing the middleslab.
 9. The method of making an ozone generator of claim 1, wherein theplacing of a first high-voltage electrode on the outside surface of thetop slab, and a second high-voltage electrode on the outside surface ofthe bottom slab, additionally comprises placing the first high-voltageelectrode and the second high-voltage electrode on a flat side of therespective slab, in each case, substantially directly over the locationof the discharge chamber.
 10. The method of making an ozone generator ofclaim 9, wherein the placing of a first high-voltage electrode on theoutside surface of the top slab, and a second high-voltage electrode onthe outside surface of the bottom slab, additionally comprises placingthe first high-voltage electrode and the second high-voltage electrod ina generally centrally located position with respect to the outline ofthe discharge chamber underneath.
 11. The method of making an ozonegenerator of claim 1, additionally comprising repeating act a) throughf) with at least a second set of slabs, and teaming together the firstset of slabs with the at least second set of slabs, when assembled, in aserial or parallel, or a combination of serial and parallel,configuration to provide enhanced ozone production.
 12. The method ofmaking an ozone generator of claim 2, wherein the placing of a firsthigh-voltage electrode on the outside surface of the top slab, and asecond high-voltage electrode on the outside surface of the bottom slab,additionally comprises placing the first high-voltage electrode and thesecond high-voltage electrode on a flat side of the respective slab, ineach case, substantially directly over the location of the dischargechamber.
 13. The method of making an ozone generator of claim 12,wherein the placing of a first high-voltage electrode on the outsidesurface of the top slab, and a second high-voltage electrode on theoutside surface of the bottom slab, additionally comprises placing thefirst high-voltage electrode and the second high-voltage electrod in agenerally centrally located position with respect to the outline of thedischarge chamber underneath.
 14. The method of making an ozonegenerator of claim 2, additionally comprising repeating act a) throughf) with at least a second set of slabs, and teaming together the firstset of slabs with the at least second set of slabs, when assembled, in aserial or parallel, or a combination of serial and parallel,configuration to provide enhanced ozone production.